Two-sided abrasive tool and method of assembling same

Abstract

An abrasive tool and method for assembling same includes a first base having a front surface and a back surface and a second base having a front surface and a back surface. A first perforated sheet has a front surface and a back surface, the back surface of the first perforated sheet being bonded to the front surface of the first base. A second perforated sheet has a front surface and a back surface, the back surface of the second perforated sheet being bonded to the front surface of the second base. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet, and a second layer of abrasive grains is bonded to the front surface of the second perforated sheet. The back surface of the first base is bonded to the back surface of the second base. The back surfaces of the bases may be bonded by sonic welding.

What is claimed is: 
     
       1. An abrasive tool, comprising: a first base having a front surface and a back surface;   a second base having a front surface and a back surface;   a first perforated sheet having a front surface and a back surface, the back surface of the first perforated sheet bonded to the front surface of the first base;   a second perforated sheet having a front surface and a back surface, the back surface of the second perforated sheet bonded to the front surface of the second base;   a first layer of abrasive grains bonded to the front surface of the first perforated sheet; and   a second layer of abrasive grains bonded to the front surface of the second perforated sheet;   wherein the back surface of the first base is bonded to the back surface of the second base.   
     
     
       2. The abrasive tool according to claim 1 wherein the back surface of the first base is bonded to the back surface of the second base by sonic welding. 
     
     
       3. The abrasive tool according to claim 1 wherein the first and second perforated sheets have perforations arranged to form an interrupted cut pattern. 
     
     
       4. The abrasive tool according to claim 1 wherein the first base and the second base comprise a plastic material. 
     
     
       5. The abrasive tool according to claim 1 wherein the back surfaces of the first and second bases are joined by sonic weld joints on the back surfaces of the first and second bases. 
     
     
       6. The abrasive tool according to claim 1 wherein the front surfaces of the first and second bases are bonded to the back surfaces of the first and second sheets respectively by injection molding. 
     
     
       7. The abrasive tool according to claim 1 wherein the perforations in the perforated sheets are counterbored. 
     
     
       8. The abrasive tool according to claim 7 wherein the front surfaces of the first and second bases are bonded to the back surfaces of the first and second sheets respectively by injection molding. 
     
     
       9. The abrasive tool according to claim 8 wherein the injection molded bond anchors the first and second perforated sheets to the first and second bases respectively by the counterbored perforations. 
     
     
       10. The abrasive tool according to claim 1 wherein the first and second perforated sheets have perforations in a portion less than the entirety of the sheets. 
     
     
       11. The abrasive tool according to claim 1 wherein the tool is a file. 
     
     
       12. The abrasive tool according to claim 1 wherein the first and second layers of abrasive grains are bonded to the front surfaces of the first and second perforated sheets respectively by a nickel plating. 
     
     
       13. The abrasive tool according to claim 1 wherein the first and second layers of abrasive grains are bonded to the front surfaces of the first and second perforated sheets respectively by a brazing material. 
     
     
       14. The abrasive tool according to claim 1 wherein the first and second layers of abrasive grains have two different degrees of abrasiveness. 
     
     
       15. The abrasive tool according to claim 1 wherein the first and second layers of abrasive grains have the same degree of abrasiveness. 
     
     
       16. An abrasive tool, comprising: a first base having a front surface and a back surface, the back surface comprising sonic weld joints;   a second base having a front surface and a back surface, the back surface comprising sonic weld joints;   a first perforated sheet having a front surface and a back surface, the back surface of the first perforated sheet bonded to the front surface of the first base;   a second perforated sheet having a front surface and a back surface, the back surface of the second perforated sheet bonded to the front surface of the second base;   a first layer of abrasive grains bonded to the front surface of the first perforated sheet; and   a second layer of abrasive grains bonded to the front surface of the second perforated sheet;   wherein the back surface of the first base is bonded to the back surface of the second base by sonic welding.   
     
     
       17. A method of assembling an abrasive tool, comprising: providing a first base having a front surface and a back surface, a second base having a front surface and a back surface, a first perforated sheet having a front surface and a back surface, and a second perforated sheet having a front surface and a back surface;   bonding the front surface of the first base to the back surface of the first perforated sheet;   bonding the front surface of the second base to the back surface of the second perforated sheet;   bonding a first layer of abrasive grains to the front surface of the first perforated sheet;   bonding a second layer of abrasive grains to the front surface of the second perforated sheet; and   bonding the back surfaces of the first and second bases.   
     
     
       18. The method of claim 17 wherein bonding the back surfaces of the first and second bases comprises sonic welding. 
     
     
       19. The method of claim 17 wherein the bonding of the first and second bases to the first and second perforated sheets respectively is performed prior to the bonding of the first and second layers of abrasive grains. 
     
     
       20. The method of claim 17 wherein the first and second perforated sheets have perforations arranged to form an interrupted cut pattern. 
     
     
       21. The method of claim 17 wherein the first base and the second base comprise a plastic material. 
     
     
       22. The method of claim 17 wherein the back surfaces of the first and second bases are joined by sonic weld joints. 
     
     
       23. The method of claim 17 wherein the front surfaces of the first and second bases are bonded to the back surfaces of the first and second sheets respectively by injection molding. 
     
     
       24. The method of claim 17 wherein the perforations in the perforated sheets are counterbored. 
     
     
       25. The method of claim 17 wherein the first and second perforated sheets have perforations in a portion less than the entirety of the sheets. 
     
     
       26. The method of claim 17 wherein the first and second layers of abrasive grains have two different degrees of abrasiveness. 
     
     
       27. The method of claim 17 wherein the first and second layers of abrasive grains have the same degree of abrasiveness. 
     
     
       28. The method of claim 17 further comprising grinding the front surfaces of the first and second perforated sheets prior to the bonding of the first and second layers of abrasive grains to the first and second perforated sheets respectively. 
     
     
       29. The method of claim 17 wherein the bonding of the first and second layers of abrasive grains to the front surfaces of the first and second perforated sheets respectively comprises electroplating. 
     
     
       30. The method of claim 17 wherein the bonding of the first and second layers of abrasive grains to the front surfaces of the first and second perforated sheets respectively comprises anodizing. 
     
     
       31. The method of claim 17 wherein the bonding of the first and second layers of abrasive grains to the front surfaces of the first and second perforated sheets respectively comprises brazing.